Movable injection passages during the manufacturing of laminates

ABSTRACT

The present invention relates to a method of manufacturing a laminate with the formation of underpressure between a mould ( 103 ) and a vacuum foil ( 105 ) and supply of resin from injection areas to the layers of the laminate situated in the mould. The novel aspect according to the invention comprises movement of the injection areas while the resin is supplied, This is accomplished by use of a movable suction unit ( 200 ) which is arranged on top of the vacuum foil and which, by means of an underpressure between the suction unit and the vacuum foil, forms injection areas for supply of the resin, which can be moved by moving the suction unit. The invention further relates to such movable suction unit and the use thereof in the manufacture of laminates.

The invention relates to a method of manufacturing a laminate comprisingthe formation of an underpressure between a mould and a vacuum foil andsupply of resin from injection areas to the layers of the laminateplaced in the mould. The invention further relates to a unit for thesupply and distribution of resin during the manufacture of laminates bythe above-mentioned method.

BACKGROUND

The so-called VARTM-technique (Vacuum Assisted Resin Transfer Molding)is a method of manufacturing laminates wherein an underpressure is usedfor impregnating the various layers of the laminate with resin. Thelayers are arranged in a single-sided open mould part, on top of which anumber of inlet passages are distributed and, at the top, a vacuum foilwhich is sealed along the edges of the mould part. Then a vacuum isapplied in the mould cavity between the foil and the mould part, and theresin is infused or injected from the inlet passages. Following completeor partial hardening of the laminate, the foil is removed and optionallyalso the inlet passages, and the laminate can be discharged from themould.

In order to ensure optimal properties of the finished laminate, it isimportant that all the layers in laminate are completely impregnatedwith resin and that there are no dry pockets. It is therefore importantto distribute and arrange the inlet passages across large parts of thelaminate surface in such a manner that the resin supply can becontrolled and regulated optimally, which, however, often turns out tobe difficult in practice. Simultaneously with ensuring a completeimpregnation of all the layers, it is also desirable to be able toperform the injection as quickly as possible.

U.S. Pat. No. 5,328,656 teaches a method of performing vacuum infusionof large shell structures, wherein one or more inlet tubes are conveyedinto a cavity in the laminate, following which the cavity is filled frombelow with a monomer and a hardener. During the filling procedure, thetube is gradually withdrawn to the effect that the outlet end of thetube is continuously just below the flow front. Hereby an even andcomplete injection into the mould cavity is ensured. However, it is notpossible by the above-referenced VARTM-process to move the inletpassages around as they are kept in place by the underpressure and thepressure of the vacuum cloth.

Yet a problem which is associated with the VARTM-process is the largewaste of resin involved in the method, since, following the injection,the resin-filled inlet passages either remain on the top face and thenpartake as a very resin-rich part of the laminate without contributingpositively to the properties of the laminate or are removed from thelaminate following hardening and must be discarded. By using collapsibleinlet bags the passages can be emptied of resin by the pressure of thevacuum foil following finished injection, and the resin waste can thusbe reduced. However, this solution presupposes that the vacuum foil isvery elastic in order for the inlet passages to open and make room forthe resin to enter.

WO 2004/000536 discloses a method of forming a system of temporary inletpassages, wherein a plate consisting of a number of interconnectedspacers are arranged in a pattern on top of the vacuum cloth and iscovered by one or two further vacuum foils. Hereby the lowermost foilcan be sucked up between the spacers to the effect that inlet passagesare formed between the material layers and the vacuum foil. However, thedescribed system is complex in that several vacuum foils are used and,likewise, it is required to provide a plate or mat of spacers thatspecifically fits the shape of the laminate to be produced. Moreover,that method does not solve the problem either of ensuring completeimpregnation of the laminate without dry pockets.

OBJECT AND DESCRIPTION OF THE INVENTION

It is the object of the invention to provide a method of vacuuminjecting laminates with resin whereby the above-referenced problems ofincomplete and deficient impregnation are avoided. It is a furtherobject to reduce the resin waste from the resin filled inlet passagesfollowing ended injection.

Thus, the present invention relates to a movable suction unit forforming an injection area for resin during the manufacture of laminates,said suction unit being arranged on top of the vacuum foil. The suctionunit comprises an upwardly arched underside and means for formingunderpressure between the underside and the subjacent vacuum foil to theeffect that the suction unit is movable during the manufacture.

Hereby the advantageous aspect is accomplished that the resin injectioncan be kept just at or right after the flow front of the resin, wherebythe pressure gradient is increased markedly. This further entails thatthe injection can be performed more quickly and that, due to theincreased pressure gradient, the injection becomes more efficient andcomplete. It is a further considerable advantage of the movable suctionunit that the injection areas can be emptied substantially completely ofresin, quite simply by interrupting the suction on the suction unit.Hereby the relatively large amounts of resin that are otherwise wastedin conventional inlet passages and bags are saved. Likewise, it is anoption to continuously open and close the resin supply from variousindividual suction units as desired during the manufacturing process bycontrolling the suction on the suction unit. Hereby it is possible, inan extremely simple but efficient manner, to control and regulate theresin injection in local areas of the mould. By using one or moremovable suction units according to the invention, the often complex andtime-consuming laying of stationary injection passages is avoided, whichis otherwise required to ensure complete injection. The movable suctionunits described herein are also advantageous in that they can bemanufactured at low production costs and may furthermore be advantageousin that they can be reused for the manufacture of other laminates andthey are, to a wide extent, independent of the shape of the laminate.

Moreover the invention relates to a movable suction unit according tothe above, wherein the upwardly arched underside of the suction unitforms an elongate passage or an inversed dish. According to the former,the resin can be conveyed efficiently far in over the laminate and thusbe injected across a large area. An inversed dish-shape is advantageousfor injecting limited areas, eg for subsequent injection of dry pockets.

By a further embodiment of the invention, the means for formingunderpressure on the movable suction unit is connected to at least oneperforation in the upwardly arched underside. By sucking through anumber of perforations in the underside of the suction unit, the vacuumfoil can more easily and more reliably be sucked upwards to follow theentire underside. Hereby the suction necessary for lifting the vacuumfoil is also minimised.

A further embodiment of the invention comprises at least one passageleading into at least a part of the abutting face of the suction unitagainst the subjacent vacuum foil, through which passage lubricants aresupplied, whereby the friction against the vacuum foil is reduced duringmoving. Hereby a more easily movable suction unit is accomplished evenin case a relatively large underpressure is applied onto the suctionunit or onto the mould cavity.

According to yet an embodiment the movable suction unit comprises atleast one passage leading into the upwardly arched underside for supplyof resin. Hereby the resin can be supplied locally through the suctionunit and a perforation in the vacuum foil, whereby the suction unit canbe arranged anywhere on top of the laminate as needed.

The invention further relates to an embodiment, where the movablesuction unit is manufactured at least partially in a flexible material,such as a soft plastic, rubber or the like. Thus, the suction unit canfollow the surface of the laminate even in case of curved or evendouble-curved faces. The flexibility further entails that the suctionunit can be produced as a standard unit and reused for the manufactureof laminates having different shapes. Likewise, it is possible to allowa flexible suction unit to follow a curving course across the laminatesurface, whereby the injection area can, to an even greater extent, bemoved to the place where it is desired or necessary.

The present invention also relates to a method of manufacturing alaminate comprising formation of an underpressure between a mould and avacuum foil and supply of resin from injection areas to the layers ofthe laminate arranged in the mould, said method further comprisingmoving the injection areas during the supply. Moreover, one embodimentof the invention relates to a method of manufacturing a laminateaccording to the above, further comprising use of a movable suction unitaccording to the above. The advantages of this are as described above inthe context of the movable suction unit.

According to yet an embodiment of the invention the above-describedmethod further comprises to arrange the movable suction unit on top ofthe vacuum foil; to form an injection area underneath the suction unitby application of underpressure between the vacuum foil and the suctionunit; to distribute resin from the injection areas; and to move theresin distribution by moving the suction unit.

Further, the invention relates to a method of manufacturing a laminateaccording to the above, wherein the underpressure between the vacuumfoil and the suction unit is formed before the underpressure between themould and the vacuum foil is formed. Hereby it is accomplished that thevacuum foil can be sucked into the suction end at an even moderateunderpressure, since it does not have to also cancel out anunderpressure in the mould cavity. Moreover, the injection areaunderneath the suction unit can hereby be formed independently of theelasticity of the vacuum foil.

According to yet an embodiment of the invention, the underpressure isformed between the vacuum foil and the suction unit after the formationof underpressure between the mould and the vacuum foil.

The invention further describes a method according to one or more partsof the above, wherein at least a part of the suction unit is movedduring the resin supply in a direction at least partially in the wake ofthe flow front of the resin. Hereby a maximal pressure gradient ismaintained during the injection, whereby the efficiency and speedthereof are increased.

A further embodiment of the invention relates to a method ofmanufacturing a laminate according to the above, wherein an end of thesuction unit is moved along an edge of the mould. Hereby the resin canbe supplied to the injection area underneath the suction unit from oneor more intakes that can be arranged along the edge of the mould part ina simple and efficient manner.

Yet an embodiment of the invention relates to a method of manufacturinga laminate in accordance with the above, wherein at least a part of thesuction unit is moved for subsequent injection of another part of thelaminate. Hereby dry and incompletely impregnated areas in the laminatecan be avoided if they are detected during the injection procedure.

A further embodiment of the invention relates to a method ofmanufacturing a laminate in accordance with the above, furthercomprising arrangement of a manifold with resin supply underneath thevacuum foil. Hereby resin supply to the injection areas formed by themovable suction units is ensured, without them necessarily extending tothe edge of the mould.

By a further embodiment of the method according to the invention, resinis supplied from the suction unit through one or more holes in thevacuum foil, whereby the resin can be injected into any local area ofthe laminate without depending on whether a manifold or a tube withresin supply underneath the vacuum foil is situated near the suctionunit.

Finally the present invention also relates to the use of a movablesuction unit for resin supply in the manufacture of a laminate, saidsuction unit being described by the previously mentioned embodiments.The advantages of this are as described earlier for the manufacturingmethod and the movable suction unit.

BRIEF DESCRIPTION OF THE DRAWINGS

In the following the invention is described with reference to thefigures, wherein

FIG. 1 shows the manufacture of a laminate by a conventional VARTMprocess;

FIG. 2 shows the manufacture of a laminate by use of a movable suctionunit according to the invention;

FIGS. 3-4 show various kinds of movable folds on a vacuum foil that forminlet passages;

FIGS. 5-7 show different cross sections of a suction unit;

FIG. 8 shows a cross section of a suction unit in greater detail;

FIG. 9 shows a suction unit which is moved along a manifold with resinsupply; and

FIG. 10 shows a movable suction unit according to the invention withsupply of resin through the suction unit.

DESCRIPTION OF EMBODIMENTS

FIG. 1 shows the manufacture of a laminate 101 by a so-called VARTMprocess (Vacuum Assisted Resin Transfer Moulding) according to the priorart. A number of layers 102 for the laminate are laid in a single-sidedmould part 103. On top of this, inlet passages 104 are arranged fromwhich the resin is distributed and infused or injected down and outthrough layers 102. The layers and inlet passages are covered by avacuum cloth or foil 105 that can be secured in various ways around theedge of the mould (not shown) to the effect that the mould cavitybetween the vacuum foil and the mould part is sealed. Before theinjection is started, vacuum is applied to the mould cavity. This can beaccomplished in various ways, eg from the edge of the mould or viasuction from the underside of the layers through holes in the mould part103. Then the resin is distributed via the inlet passages andimpregnates the layers 12 either exclusively by infusion due to theapplied vacuum or by injection where the resin supply is alsopressurised. Following moulding and complete or partial hardening of thelaminate, the resin-filled inlet passages may either partake as aresin-rich part of the laminate and hence as a deadweight or be removed.The latter can be facilitated by arrangement of a tear-off layer withpoor adhesion underneath the injection passages. The properties of thefinished laminate greatly depend on all layers being impregnated all theway through with resin. To ensure this and to avoid pockets where thelayers are not impregnated, the inlet passages 104 are usuallydistributed across the layers, to the effect that the resin distributionbecomes as even and uniform as possible, and likewise to the effect thatthe injection can be performed as quickly as possible for the sake ofprocess time.

According to the present invention, the injection passages are mademovable by using movable suction units or external inlet profiles 200that are arranged on top of the vacuum foil 105 as illustrated in FIG.2. The underside of the suction unit is upwardly curved 203 (see alsosubsequent figures) and the suction unit is coupled to a suction (notshown) to the effect that the vacuum foil 105 is sucked there into andforms a fold 204 or a bulge. In this manner the vacuum foil itselfconstitutes an injection passage 104 in which the resin can flow andinject layers 102 in the mould cavity. The resin can be suppliedunderneath the fold 204 on the vacuum foil 105 from one or more supplypassages that may be situated eg along one or more edges of the mould103. The magnitude of the suction on the suction unit may either begreater than the underpressure applied on the mould cavity, whereby thevacuum foil 105 will be pressed completely close to the underside 203 ofthe suction unit. Alternatively the suction on the suction unit may beof such magnitude that the underpressure in the mould cavity iscompletely or approximately equalised. In that case the vacuum foilcould be lifted upwards into the suction unit by the resin when thelatter is supplied. The suction can be applied to the suction units bothbefore and after the formation of an underpressure in the mould cavity,which will, depending on the elasticity of the foil, cause the folds andhence of the inlet passages to be larger or smaller in cross section.

As outlined by arrows 201 in FIG. 2, the suction unit 200 enables movingor pushing of the fold 204 on the vacuum foil 105 and hence theinjection passage 104 around across the surface of the laminate 101.Hereby the injection passage may eg be held close to the flow front 202of the resin, whereby a large pressure gradient can be maintained withan ensuing quicker and more efficient injection. It is thus possible tomove the resin injection to another area of the laminate and performsubsequent injection if, in that place, the impregnation wasinsufficient the first time around. Both during and after the injection,each individual injection passage 104 can be opened and closed anunlimited number of times and independently of the other injectionpassages, quite simply by regulating or optionally removing the suctionfrom the associated suction unit 200. Hereby the underpressure in themould cavity presses the vacuum foil together and downwards towards themould, whereby the remaining resin from the inlet passage is pressed outand down into the laminate. The large amount of resin wasted whenconventional stationary and more or less fixed inlet passages are usedis also obviated by use of the inlet passages according to theinvention.

A further advantage of the above-disclosed method resides in the inletbags or tubes as such being omitted in the production which couldotherwise, in the prior art, be used only once and then be discarded.Conversely the suction units according to the present invention can bereused for subsequent manufactures of laminates in an extent which is,in principle, unlimited. The suction units according to the inventionare moreover not adapted specifically to the relevant mould part andshape of the laminate being produced, but rather it can be used inlargely all moulds without needing adaptation. If the suction units aremade of a flexible material, such as rubber of soft plastics, it mayalso follow even curved or double-curved surfaces. This also enablesthat the suction unit can be flexed while being moved forwards, whichmay be advantageous eg for moving around protruding parts on thelaminates, inserts or the like.

According to a further embodiment of the invention, a vacuum passage isarranged and moved next to an injection passage during the resininjection into the laminate, whereby the pressure gradient and hence therate of injection is further increased. The suction unit according tothe invention can likewise be used to produce movable vacuum passages orareas by coupling the fold on the vacuum foil to a further suction.

FIGS. 3 and 4 illustrate how a fold 204 on a vacuum cloth 105 whichforms a movable inlet passage 104 can be moved or pushed across thesurface of the laminate 101. The suction unit which lies across andlifts the vacuum foil is not shown for the sake of clarity. In FIG. 3 afold 204 or bulge is outlined that extends transversally of the entiresurface with a uniform cross section all the way. The arrows 301illustrates how the fold 204 (by means of the suction unit) does notnecessarily have to be pushed evenly throughout its entire length, butmay very well be moved more at the one end than at the other.

The fold 204 illustrated in FIG. 4 does not extend all the waytransversally of the laminate 101, rather it stops and evens out 401somewhere at the middle. Correspondingly, the suction unit according tothe invention need not reach all the way across the laminate, but mayhave smaller dimensions. Like the fold shown earlier, the fold 204 andinjection passage 104 may also be moved about in any random way acrossthe surface of the laminate 101. The only limitation to the pattern ofmovement of the suction unit is that the injection passage or area 104formed by the fold in the foil underneath the suction unit must beconnected to the resin supply. This may be accomplished eg by allowingthe one end of the channel-shaped suction unit follow an edge of themould part, where a tube with resin supply is laid underneath the vacuumfoil. Another embodiment of this is shown later, in FIG. 9.

In FIGS. 5-7 various suitable configurations of a suction unit 200 areshown in cross section. The suction unit is constructed as an elongatepassage with an upwardly arched or upwardly curved underside 203, intowhich the vacuum foil (not shown) is sucked. In FIGS. 5 and 6 theunderside comprises circular sections 501 while, as shown in FIG. 7, itmay also consist of straight lines 701 with rounded transitions 502. Inorder to be able to move the suction unit around while the vacuum foilis sucked there into, any corners and edges 502 on the underside 203 ofthe suction unit are rounded, whereby it is also avoided that the vacuumfoil is damaged. The configuration of the sides and surface of thesuction unit is of no consequence to the invention, but may, of course,be configured such that the suction unit becomes easy to handle andmove.

The suction on the suction unit is not shown in the figure, but may beconnected to the cavity as such formed by the upwardly arched underside203. According to a further embodiment, as illustrated in FIG. 8,underpressure is sucked in a cavity 801 in the suction unit as such,from where the underpressure is taken on to the entire or parts of theunderside of the suction unit via a number of holes or perforations 802as shown by arrows 803. The shown embodiment of the suction unit isfurther configured with two lubrication passages 804. From there alubricant is supplied to the vacuum foil, whereby the suction unit canmore easily be moved or pushed. As lubricant various oils, Vaseline orthe like can be used. Here the lubricant passages 804 are arranged onthe abutment faces 805 of the suction unit, but they may also bearranged elsewhere on the underside 203. The suction unit may bemanufactured of various materials, such as metal, plastics or rubber. Bymanufacturing the suction unit from a flexible material, theadvantageous aspect is accomplished that the suction unit is able tobetter follow the surface of the laminate with small or largerirregularities. Moreover, a flexible suction unit may also be usedduring the manufacture of laminates with curved or double-curved surfacewithout particular adaptation of the unit.

FIG. 9 shows the surface of a laminate 101 during resin injection with asuction unit 200 according to the invention arranged on top of thevacuum foil 105. In this embodiment the resin is supplied in a manifold901 which is laid on top of the laminate underneath the vacuum foil. Themanifold 901 is provided with holes 902 down along its length andprimarily at its upper portion. Then the resin will flow out of theseholes 902, but only to a very limited extent or not at all for as longas the vacuum foil 105 covers the holes 902. By taking the suction unit200 with applied suction along the manifold 901 and, as outlined in thefigure by arrows 905, the vacuum foil is lifted upwards from themanifold and the resin may flow out into the inlet passage formed by thefold 204 on the vacuum foil which is sucked into the suction unit. It ishereby possible to move a suction unit around and inject centrally onthe laminate without having to reach and follow an edge of the mouldpart.

According to yet further embodiments, the suction unit may be designedin other shapes than that of elongate passages. FIG. 10 shows a movablesuction unit 200 according to the invention, where the underside 203 ofthe suction unit is configured as an inversed dish, and the vacuum foilthus bulges 1002 upwards into the suction unit 200 when an underpressureis formed between it and the foil. If the suction unit is not moved, theresin will flow approximately radially from the suction unit as shown bythe outlined flow front 202. Here the resin may likewise be supplied tothe injection area 104 underneath the vacuum foil 105 via a pipe or atube 1001 conveyed through the suction unit 200 and through a hole inthe vacuum foil 105 which is made temporarily underneath the suctionunit. Following injection the hole can easily be patched again with egtape. This suction unit is particularly advantageous for subsequentinjection into areas where the resin injection was incomplete the firsttime around.

It will be understood that the invention as taught in the presentspecification and figures can be modified or changed while continuing tobe comprised by the scope of protection conferred by the below claims.

1-7. (canceled)
 8. A method of manufacturing a laminate comprisingformation of underpressure between a mould and a vacuum foil and supplyof resin from injection areas to the layers of the laminate placed inthe mould, said method being characterised in further comprising movingthe injection areas during the supply.
 9. A method of manufacturing alaminate according to claim 8, characterised in further comprising useof a movable suction unit.
 10. A method of manufacturing a laminateaccording to claim 8, characterised in further comprising: arranging themovable suction unit on top of the vacuum foil; forming an injectionarea underneath the suction unit by application of 15 underpressurebetween the vacuum foil and the suction unit; distributing resin fromthe injection areas; and moving the resin distribution by moving thesuction unit.
 11. A method of manufacturing a laminate according toclaim 8, characterised in that the underpressure between the vacuum foiland the suction unit is formed before the formation of underpressurebetween the mould and the vacuum foil.
 12. A method of manufacturing alaminate according to claim 8, characterised in that the underpressurebetween the vacuum foil and the suction unit is formed after theformation of underpressure between the mould and the vacuum foil.
 13. Amethod of manufacturing a laminate according to claim 8, characterisedin that at least a part of the suction unit is moved during the resinsupply in a direction at least partially in the wake of the flow frontof the resin.
 14. A method of manufacturing a laminate according toclaim 8 characterised in that an end of the suction unit is moved alongan edge of the mould.
 15. A method of manufacturing a laminate accordingto claim 8 characterised in that at least a part of the suction unit ismoved to after-injection in another part of the laminate.
 16. A methodof manufacturing a laminate according to claim 8, characterised infurther comprising placing a manifold with resin supply underneath thevacuum foil.
 17. A method of manufacturing a laminate according to claim8 characterised in further comprising supply of resin from the suctionunit through one or more holes in the vacuum foil.
 18. Use of a movablesuction unit for resin supply in the manufacture of a laminate, saidsuction unit being described by claim 8.